Pad for Hot Beverage and Apparatus and Method for Manufacturing Thereof

ABSTRACT

The invention relates to a pad for use in a beverage machine for preparing a warm beverage, a system therefor, and a method for manufacturing such pads. The pad includes: a first sheet having a surface area, wherein the surface area of the first sheet is provided with flow passages that are positioned at or near the outer perimeter of the first sheet; and a second sheet having a surface area, wherein the surface area of the second sheet is provided with one or more flow passages that are positioned at or near the centre of the second sheet. The first sheet and the second sheet are connected to each other at or near the outer perimeter for forming an inner space for holding the raw material that is usable for preparing the beverage. Substantially the entire surface area of the first and/or second sheet is impermeable to the flow of pressurized liquid. The impermeable surface area and the flow passages cooperate for forcing the flow of pressurized liquid to flow substantially in a direction that is parallel to the surface areas through the raw material in the pad.

The present invention relates to a pad for use in making a hot beverage such as coffee, including espresso, latte macchiato, caffè latte, caffè macchiato, cappuccino etc., and hot chocolate, including caffè choco etc., particularly to the preparation of a coffee using pads with ground coffee, and to an apparatus and method for manufacturing such pads.

Preparing hot beverages such as coffee or hot chocolate using pads with raw material is known from practice. In use, the pad is placed in a beverage machine and provided with a pressurized liquid that forces the liquid to flow through the pad to obtain the beverage.

A problem of the known pads when used in existing beverage machines is that the flow through the pad, and especially the flow through the raw material contained therein, is not optimal and as a result the extraction from the raw material is not uniform.

The present invention aims to provide a pad for preparing a hot beverage, such as coffee or hot chocolate that obviates or at least reduces the abovementioned problems.

This object is achieved by a pad for use in a beverage machine for preparing a warm beverage, the pad being configured for holding a raw material through which a pressurized flow of liquid is forced for preparing the beverage, the pad comprising:

-   -   a first sheet having a surface area, wherein the surface area of         the first sheet is provided with flow passages that are         positioned at or near the outer perimeter of the first sheet;     -   a second sheet having a surface area, wherein the surface area         of the second sheet is provided with one or more flow passages         that are positioned at or near the centre of the second sheet;         and     -   wherein the first sheet and the second sheet are connected to         each other at or near the outer perimeter for forming an inner         space for holding the raw material that is usable for preparing         the beverage.     -   wherein substantially the entire surface area of the first         and/or second sheet is impermeable to the flow of pressurized         liquid, and     -   wherein the impermeable surface area and the flow passages         cooperate for forcing the flow of pressurized liquid to flow         substantially in a direction that is parallel to the surface         areas through the raw material in the pad.

The phrase “connected to each other” as used in the invention for purposes of the invention also includes similar terms as joining together, sealing and/or attaching, preferably in a durable manner. Most preferably, it includes sealing of the first and second sheet to form a fluid-tight connection that holds under pressure and/or heat. The connection and/or sealing may be formed using a variety of suitable manufacturing techniques may amongst others include gluing, hot melting, sewing and/or cross-linking.

The pad according to the invention has the advantage that a flow is achieved in a direction that is substantially parallel to the surface areas. In most applications this means that in use a substantially horizontal flow of pressurized liquid is achieved through the pad. This enables fully utilizing the raw material contained in the inner space of the pad. In this text the term horizontal in relation to the flow direction through the pad is to be interpreted as substantially parallel to the surface areas.

The improved utilization of the raw material is the result of the fact that at least one of the first and second sheets has a surface area that is at least partially impermeable to pressurized liquid, which forces the flow of pressurized liquid to flow through the pad in a substantially horizontal direction. The pad is placeable in a beverage machine with the first sheet facing towards a pressurized liquid supply of the machine or, alternatively, with the second sheet facing towards the pressurized liquid supply.

For example, in a first situation, in which the pad is placed with the first sheet facing towards a centrally positioned liquid supply/inlet of a beverage machine, the pressurized liquid is redirected, preferably by the impermeable surface area of the first sheet, towards the flow passages near the outer edge. This is achieved regardless of the exact positioning of the liquid inlet in the beverage machine. When entering the pad, the flow of pressurized liquid is directed inwardly towards the preferred centralised outlet/flow passage(s) in the second sheet and the preferred central outlet of the beverage machine. The second sheet is optionally also substantially impermeable to direct or guide the flow. In addition or alternatively, directing or guiding the flow is the result of the bottom part of the pad holder. In any case, as a result, in use a substantially horizontal flow through the pad is achieved.

For example, in a second situation, in which the pad is placed in a beverage machine with the second sheet facing towards a liquid supply/inlet of the beverage machine, the flow of pressurized liquid, after having centrally entered the pad through the flow passage(s) in the second sheet, encounters the impermeable surface of the first sheet and/or the bottom of the pad holder and is forced to flow in an outward direction towards the flow passages positioned near the outer edge. After passing the decentrally positioned flow passages, the product may flow underneath the pad towards a central outlet of the beverage machine. As a result, a substantially horizontal flow through the pad is achieved.

Due to the substantially horizontal flow in the pad, the raw material is more efficiently used than in existing pads and the amount of raw material that is needed to achieve a similar or higher quality beverage is reduced compared to existing pads.

Another advantage of the pad according to the invention is that the formation of preferential flow paths in the raw material is substantially prevented. When using an existing pad known from practice, the flow of pressurized liquid from the liquid inlet of a beverage machine often slightly displaces raw material in the pad upon entering the pad, therewith forming a flow path having a lower flow resistance. Because liquid flows along the path of least resistance, the pressurized liquid is inclined to form and subsequently follow the path of the least resistance. This effect is substantially prevented in the pad according to the invention, because the flow of pressurized liquid in the pad is forced along a substantially horizontal direction by the impermeable surface of the first sheet that involves a longer path through the raw material. Thus, a more efficient use of the raw material is achieved.

Yet another advantage of the pad according to the invention is that the impermeable surface of the first and/or second sheet preferably provides an increased stiffness to the pad, which reduces crumpling and/or creasing of the pad. Existing pads are relatively flexible, which, when introducing the pad into the beverage machine, increases the risk of crumpling and/or creasing of the pad. As a result, preferential flow paths may already be formed and/or the sealing of the pad in the beverage machine is reduced, allowing a flow of pressurized liquid to bypass the pad entirely. The pad according to the invention has in increased stiffness, which reduces the amount of crumpling and/or creasing, making it easier to correctly introduce the pad in the beverage machine. Therewith the risk of leakage along the seal is reduced.

Furthermore, the additional impermeable surface or surfaces contributes to maintaining the raw material in the pad fresh. This improves the overall quality assessment by a consumer.

Moreover, the pad according to the invention can advantageously be used in existing beverage machines without having to adapt the beverage machines.

The size of the impermeable surface and the exact positioning of the flow passages are chosen such that a substantially horizontal flow is achieved through the raw material in the pad. According to the invention, this may be achieved in various ways.

In an embodiment, the flow passages in the first sheet may comprise a ring at or near an outer edge of the pad, which forms a single circular flow passage for the pressurized flow of liquid to flow into the pad. In a different embodiment, multiple flow passages are positioned near or at the outer edge of the first sheet, which for example may be used when the preferred impermeable surface is substantially equal to the surface of the first sheet. Alternatively, only a limited number of flow passages may be applied to the surface area of the first sheet.

The surface of the second sheet preferably is provided with a single flow passage for allowing a flow of liquid to exit the pad or may be provided with a number of flow passages that can for example also be configured to be positioned in a ring in the second sheet. Preferably, such a ring of flow passages would be near or at the centre of the pad.

Moreover, as was already mentioned, the pad according to the invention may be inserted in a beverage apparatus with the first sheet facing upwards, i.e. in the direction of a liquid supply/inlet by the apparatus, or with the first sheet facing downwards towards a liquid outlet of the apparatus. The specific use is determined based on the lay-out of the flow passages and the impermeable surface on the first and/or second sheet, as well as on the lay-out of the beverage machine in which the pad is used. Preferably, a pad is provided to an end-user along with an instruction on how to use the pad and/or the orientation to be used for each type of beverage machine. Most preferably, such instructions are provided along with a brand on the pad itself.

In a presently preferred embodiment of the invention, at least a substantial part of the surface area of the first sheet is impermeable to the flow of pressurized liquid. Optionally, in addition to providing an impermeable surface on the first sheet, the second sheet may also be provided with an impermeable surface and at least one flow passage. In the preferred embodiment, in use the first sheet is facing upwards towards the liquid supply/inlet of the machine. Tests have shown that such embodiment provides an effective use of the raw material.

An advantage of providing an impermeable surface on both the first and second sheets is that the pad can be used in existing beverage apparatus having for example a decentral liquid inlet and a decentral liquid outlet, for example.

In an embodiment of the invention, the pad may be substantially circular, and a diameter of the pad may be in the range of 10 to 100 mm, preferably in the range of 35 to 75 mm, and may more preferably have a diameter of around 60 mm.

The size of the pad is preferably chosen such that it is usable in existing beverage machines. In most beverage machines circular pads having a diameter of around 60 mm are used. The form and dimensions of the pad are preferably manufactured such that they can be used in existing machines.

In an embodiment of the invention, the pad and each of the impermeable surface areas may be substantially circular and the diameter of each of the impermeable surface areas may be in the range of 10-100% of the diameter of the pad, preferably in the range of 70-100% of the diameter of the pad, and more preferably in the range of 90-95% of the diameter of the pad.

The area of the impermeable surfaces in relation to the total surface of the surface area of the sheet may advantageously be adapted specific consumer or retailer requirements. This may for example relate to the type of beverage machine for which it is used and/or the type of raw material contained in the pad. For example, in a beverage machine having a centrally placed liquid outlet, the impermeable area of the second sheet may be smaller, since the flow of pressurized liquid is forced to flow towards in a substantially horizontal direction due to the fact the outlet is centrally placed. Furthermore, the properties of the impermeable surface may also depend on the pressure that is used in the beverage machine.

In an embodiment of the invention, the first and second sheets may be manufactured from a material that is permeable to liquid, such as paper, preferably filter paper, wherein the impermeable surface area may be formed on one or both of the first and second sheets during manufacturing.

The pad according to the invention may be manufactured by providing a pad having sheets made of permeable material, such as present in existing pads, which are subsequently provided with an impermeable layer that is formed in or on the surface of the first and/or second sheet. The impermeable layer may be applied on the surface of the sheet or may be applied into the sheet, forming an integral layer therewith. The advantage of applying the impermeable surfaces area or areas to the respective sheets is that it can be applied to existing pads as well.

In an embodiment of the invention, the forming of the impermeable surface area may be performed using one of a group of: coating, spray coating, gluing, printing, rolling, stamping, hot melting or stitching.

The impermeable surface area of the sheets can be applied to the sheet using one of a variety of different techniques. The specific technique chosen for applying the impermeable surface area is preferably adapted to the type of material that is used for the impermeable surface area.

In an embodiment of the invention, the first and/or the second sheet may be manufactured from a material that is impermeable to liquid.

Alternatively, the pad may have one or both sheets manufactured from an impermeable material, which obviates the step of forming the impermeable surface area to the pad. This reduces the cost and complexity of the manufacturing process, therewith also reducing the cost of the manufactured pads.

In an embodiment of the invention, the impermeable surface area may be formed or manufactured from a material that may be one of a biodegradable plastic material, such polylactic acid (PLA), or a compostable plastic material or a thermo-compressed paper.

Preferably, the materials are also food-grade materials that are accepted and/or certified for use in food-related products.

In an embodiment, one or both of the impermeable surfaces may be provided with a relief, an embossing and/or channels for guiding the flow of pressurized liquid. The impermeable surface layers applied to the surfaces of the first and second sheets may be provided with an embossing, relief and/or channels during the manufacturing.

This may for example be executed by providing a variation in the thickness of the applied layer over the surface area. The relief or embossing for example allows a manufacturer to apply a logo, brand or even instructions in the impermeable layer. Applying a logo, brand or instructions, or any other figures and/or text onto the impermeable layer may be performed using a suitable technique, such as stamping or integral shaping during application of the impermeable layer. An advantage of such relief or embossing is that the pad may be provided with specific instructions on the use and/or how the pad is to be placed in specific beverage machines.

Optionally, the impermeable layer comprises an amount of an aromatic and/or flavouring substance. This may improve the overall appreciation of a user.

Furthermore, providing preformed flow channels in the impermeable layer or layers in the pad may provide that the flow of pressurized liquid is guided more fully along the outer side of the pad from the liquid inlet to the flow passages in the first and/or second sheet. Flow channels are preferably applied on an outer side of the pad and are preferably also applied on the side of the pad that faces the liquid inlet, although it may additionally or alternatively also be provided on the side facing the liquid outlet.

The invention also relates to a system for manufacturing coffee pads according to the invention, the system comprising:

-   -   a pad manufacturing apparatus for manufacturing pads, preferably         coffee pads, at least comprising:         -   a module for manufacturing pads;         -   a module for filling the pads with raw material; and         -   a packing device, which, when viewed in a transport             direction, is positioned downstream of the pad manufacturing             and pad filling modules;     -   a conveyor which is positioned near an outlet of the pad         manufacturing apparatus on which manufactured pads are placeable         and that is configured for transporting the pad towards a         packing device;     -   a layer application device for applying an impermeable layer to         a first and/or second surface of a pad, the impermeable layer         extending over at least part of the first and/or second surface,         wherein the device is positioned near the conveyor between the         outlet and the packing device.

The system according to the invention has the advantages and effects mentioned above for the pad according to the invention.

The system according to the invention comprises an apparatus for manufacturing existing pads and further includes an addition to the production line that is specifically adapted for forming the impermeable surface area on the sheets of the pad. In this respect, it is noted that a pad manufacturing apparatus for manufacturing (existing) pads in practice often comprises a blanking device for removing and/or punching the manufactured pads out of the feeds of base material, which often comprise semi-continuous sheets of material that are provided to a feed on a roll. Advantageously, an additional production step is preferably provided to the apparatus, the production step preferably being positioned between the last manufacturing step, for example the blanking device that punches the pads from a feed, and the packing device for packing the completed pads. The conveyor preferably is an endless conveyor on which the pads are placeable and that is positioned under an angle with the production line of the pad manufacturing apparatus. The conveyor, when placed near a blanking device of the pad manufacturing apparatus, is further preferably placed slightly underneath the blacking device to capture the punched out pads on the conveyor for subsequent transportation to the layer application device.

The layer application device may be a rotatable spray gun that is configured for spraying a coating on the first sheet of the punched out pads. The advantage of a rotatable spray gun is that the layer application device and the pad are not brought in contact with each other. Furthermore, a rotatable spray gun allows a relatively high processing speed. Other layer application devices can be used as well, such as a coating device that applies a coating to the first sheet by means of gluing or hot melting. Both the use of a (rotatable) spray gun or a coating device have the advantage that they can be used to apply the impermeable layer to the sheet when the pad is already filled with raw material without having any adverse effect on the raw material in the pad.

Furthermore, an embodiment of the layer application device may also comprise a printing device, a rolling device or a stamping device to apply the impermeable layer to the first sheet.

Alternatively, the apparatus according to the invention comprises an apparatus for manufacturing known pads, that is modified by including a material feed for manufacturing sheets completely consisting of impermeable material, for example a module for feeding thermos-compressed paper to the apparatus for manufacturing pads having a first and second sheet of which the upper surface of at least a first sheet is entirely made of impermeable material.

In an embodiment of the system according to the invention, the layer application device may be configured to apply a impermeable layer over substantially the entire first and/or second surface of the pad, and the system additionally may comprise a passage application device that, when viewed in a transport direction of the conveyor, may be positioned downstream of the layer application device and that may be configured for applying a number of flow passages in or near the impermeable layer of the pad.

The pad according to the invention may be provided with an impermeable surface that extends over substantially the entire surface of the first and/or second sheet. In this case, the apparatus is equipped with an applicator device that is specifically configured for creating and/or applying flow passages in the impermeable layer. The applicator device may remove part of the impermeable layer to create flow passages or may be configured for punching openings in the impermeable layer. However, other suitable options for providing the flow passages also fall within the scope of this embodiment of the invention.

In an embodiment of the system according to the invention, the system additionally may comprise a second layer application device that may be configured for applying an impermeable layer to another surface of the first and second surface of the pad that may be positioned opposite the other surface, and a second passage application device that, when viewed in a transport direction of the conveyor, may be positioned downstream of the second layer application device and that may be configured for applying a number of flow passages in or near the impermeable layer on the another surface of the pad.

Preferably, the conveyor is positioned such that, during operation of the apparatus, subsequently the first and/or the second sheet are provided with an impermeable layer. In a preferred embodiment, the conveyor is an endless conveyor having an upper and a lower side, wherein the pads are transported along the lower path to the upper path before being transferred to the packaging. The first layer application device is positioned near the lower side of the conveyor, whereas the preferred second layer application device is positioned near the upper side of the conveyor, for example between the lower and upper side of the conveyor and above the first layer application device when viewed in a vertical direction. This allows the impermeable surface(s) to be applied to the respective sheet(s) without having to change the orientation of the pads on the conveyor.

In an embodiment of the system according to the invention, the first and/or the second layer application device may be one of a group of a rotating spray device, a stitching device, a gluing device, a spray gun, an impregnating device, or a hot melt device.

In an embodiment of the system according to the invention, the rotation speed of the conveyor may be adapted to match the speed of the pad manufacturing apparatus.

Adapting the speed of the conveyor to the speed of the pad manufacturing apparatus provides the advantage that the conveyor becomes an integral and synchronised part of the apparatus, therewith ensuring a continuous and uninterrupted manufacturing of pads using the apparatus. It is preferred that the conveyor is controlled by a controller that is operatively coupled to a sensor unit measuring the production or processing speed of the pad manufacturing apparatus, wherein the speed of the conveyor is automatically adapted by the controller to match the speed of the pad manufacturing apparatus.

In an embodiment of the apparatus according to the invention, the apparatus may be additionally provided with an embossing device, which is configured for applying a brand, logo, picture, other type of indicator in the impermeable surface of the first and/or second sheet or for applying a number of flow channels in the surface of the impermeable layer or layers. Preferably, the embossing device forms an integral part of the first and/or second layer application device to simultaneously apply the layer and the indicator. The embossing device may however also be placed downstream and directly adjacent to the first and/or the second layer application device when viewed in a transport direction, to consecutively apply the layer and the indicator.

The application of flow channels is advantageous in that it can provide an even higher amount of flow guidance of the liquid to and through the pad, thereby fully utilizing the available raw material.

In an embodiment of the apparatus according to the invention, the layer application device is configured for applying a layer that is in the range of 0.005-1.0 mm, and more preferably in the range of 0.01-0.5 mm.

The invention also relates to a method for manufacturing pads for preparing warm beverages, preferably pads according to the invention, the method comprising:

-   -   manufacturing a pad comprising a first and a second sheet, each         of the first and second sheet having an outer surface, the         manufacturing comprising:         -   sealing the first and second sheet together near an outer             edge to form an inner space for holding a raw material;         -   filling the pad with raw material;         -   providing at least one of the first and second outer             surfaces with a layer of material that is impermeable to             pressurized liquid for, when the pad is used in a beverage             machine, creating a flow of pressurized liquid that is             substantially in a direction that is parallel to the surface             areas through the raw material in the pad; and     -   stacking the pads in a transport container for transporting the         pads to users.

The method according to the invention has the advantages and effects mentioned above for the pad and the system/apparatus according to the invention.

The method according to the invention also provides the advantage that the step of providing at least one of the first and the second outer surfaces with a layer of material that is impermeable to pressurized liquid can be performed in addition to a traditional manufacturing process for manufacturing known pads. This allows existing methods to be converted into a method according to the invention for making pads according to the invention. The cost for adapting existing processes may be relatively low, therewith obviating a price increase of the manufactured pads.

In an embodiment of the method according to the invention, the manufacturing may further comprise supplying an elongated lane of first material for forming first sheets and supplying an elongated lane of second material for forming second sheets. The method may also comprise sealing a first and a second sheet along an outer perimeter of a pad to be formed and punching out the filled pads from the lanes of elongated material.

In an embodiment of the method according to the invention, providing the layer of impermeable material may comprise one of a group of coating, spray coating, gluing, printing, rolling, stamping, hot melting, impregnating, providing a self-adhesive layer, or stitching.

In an embodiment of the method according to the invention, the method may comprise applying a first liquid impermeable layer to the first sheet, wherein the surface area of the first impermeable layer is smaller than the outer surface area of the first sheet. It may alternatively comprise applying a first liquid impermeable layer to the first sheet, wherein, if the surface area of the first impermeable layer is substantially equal to the outer surface area of the first sheet, the applying also comprises applying a number of flow passages in the first sheet near an outer edge thereof for the passage of pressurized liquid. Additionally or alternatively, the method may also comprise applying a second liquid impermeable layer to the second sheet and providing a flow passage near a centre of the impermeable layer in the second sheet to allow passage of pressurized liquid.

This embodiment has the advantage that it can be applied in conjunction with an existing method for manufacturing pads without having to adapt the process as such. Instead, the method provides an additional step in which the impermeable layer is applied to one or both of the first and second layer. Another advantage of this embodiment according to the method is that the size of the impermeable layer may be adapted to the specific requirements of a client, in that the size may be chosen to be substantially the entire surface or only a part of the surface of the respective sheet. Furthermore, the size of the impermeable layer that is applied on the respective sheets may differ for each of the respective sheets. Therewith, the method allows a large measure of flexibility and freedom with regard to the pads that are manufactured.

In an embodiment of the method according to the invention, providing at least one of the first and second outer surfaces with a layer of material that is impermeable to pressurized liquid is executed by manufacturing at least one of the first and second sheet of the pad from a material that is impermeable to pressurized liquid, the embodiment further comprising applying a number of flow passages in the impermeable sheets to allow the passage of pressurized liquid.

An advantage of the method according to this embodiment is that it requires less method steps and can therefore be performed in a smaller, cheaper installation. Furthermore, the method according to this embodiment provides an increased flexibility with regard to the material that is used, because the feed material that is used in the method for manufacturing the pads can more easily be switched.

Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings in which:

FIG. 1 shows a perspective view of an example of the pad according to the invention;

FIG. 2a shows a schematic cross-sectional view of the pad of FIG. 1;

FIG. 2b shows a schematic cross-sectional view of a second example of a pad according to the invention:

FIG. 3a shows a schematic top view of the pad of FIG. 2 a;

FIG. 3b shows a schematic bottom view of the pad of FIG. 2 a;

FIG. 4a shows a schematic top view of the pad of FIG. 2 b;

FIG. 4b shows a schematic bottom view of the pad of FIG. 2 b;

FIG. 5a shows a schematic cross-sectional view of the pad of FIG. 2a when used in a beverage machine;

FIG. 5b shows a schematic cross-sectional view of the pad of FIG. 2b in a different orientation when used in a beverage machine; and

FIG. 6 a and b shows a manufacturing line for pads according to the invention.

Pad 2 comprises first sheet 4 and second sheet 6 that are sealed together on sealing edge 8 (see FIGS. 1-4). First sheet 4 is provided with impermeable surface 10 that extends from a central point towards sealing edge 8. In this example, impermeable surface 10 extends over around 90% of the diameter of first sheet 4. Flow passages 12 that are positioned near sealing edge 8 allow passage of fluid into pad 2.

In a first example (shown in FIGS. 2a, 3a, 3b ), pad 2 is provided with a second sheet 6 that is permeable to pressurized liquid over the entire surface area of pad 2. In a second example (shown in FIGS. 2b, 4a, 4b ), second sheet 6 is provided with impermeable surface 14 that extends over substantially the entire surface area of sheet 6. Impermeable surface 14 is provided with centrally placed flow passage 16 to allow a mixture of raw material and liquid to exit pad 2.

Preferably, pad 2 can be used with first sheet 4 facing a liquid supply/inlet from a beverage machine as well as with second sheet 6 facing a liquid supply/inlet of a beverage machine. The specific orientation of pad 2 with respect to the sheet 4, 6 facing towards the liquid supply/inlet of a beverage machine depends on the specific type of beverage machine in which pad 2 is used.

Furthermore, pad 2 is configured to provide, when used in a beverage machine, a substantially horizontal flow through pad 2 that is substantially parallel to the plane of sheets 4, 6.

In a first example (shown in FIG. 5a ) a number of decentral flow passages 12 in first sheet 4 function as inlet and central flow outlet 22 of beverage machine 18, and particularly a pad holder thereof, functions as outlet.

Alternatively, a combination of a number of central flow passages as inlet and a number of decentral flow passages as outlet can be provided (see FIG. 5b ), wherein optionally both sheets 4, 6 are substantially impermeable to the liquid. In other words, pad 2 may be used in various ways to provide a substantially horizontal flow through pad 2.

In use of pad 2 in beverage machine 18, for example beverage machine 18 having central inlet 20 and central outlet 22, pressurized liquid flows on impermeable surface 10 of sheet 4 and is directed towards sealing edge 8. The pressurized liquid enters pad 2 through flow passages 12 that are present near outer edge 4 a of sheet 4 (see also FIG. 3a , FIG. 5a ) and is subsequently forced to flow substantially horizontally between impermeable surface 10 of sheet 4 and lower surface 18 a of beverage machine 18 towards centrally placed beverage machine outlet 22. The combination of pad 2 with beverage machine 18 forces the pressurized liquid to flow substantially horizontally through pad 2, thereby obtaining a more efficient extraction and/or mixing process. Moreover, pad 2 can be used in existing beverage machines without having to adapt the existing beverage machines to pad 2.

In a different example (shown in FIG. 5b ), the specific construction of pad 2 having impermeable surfaces 10, 14 positioned respectively on sheets 4, 6, forces the pressurized liquid to flow in a substantially horizontal direction through pad 2 between the impermeable surfaces 10, 14 irrespective of the position of the liquid inlet 20 and/or liquid outlet 22 of beverage machine 18. This illustrates that different embodiments and orientations can be envisaged in accordance to the present invention.

Manufacturing process 102 (FIGS. 6a, 6b ) comprises a number of conveyor belts 104 that transport pads 106 from and to a conventional pad manufacturing line 116. Pads are transferred to conveyor belt 108. Layering device 110 provides the impermeable layer to pad 106. In the illustrated embodiment one device 110 is provided. It will be understood that optionally a second device 110 can be provided to provide the other surface of pad 106 with an impermeable layer. Optionally, treatment device 112 is provided. This may involve a heating device to perform a heat treatment to the impermeable layer. In the illustrated embodiment drive system 114 connects the individual drives of conveyors 104, 108 and device 110, such that these drives are synchronized with the other components of the manufacturing line.

Alternatively, the impermeable layers are already provided on the pad material directly. This obviates the need for including separate device(s) 110. It will be understood that other methods and devices can be envisaged to provide the impermeable layer(s).

The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged. It is thus possible according to the invention to make a combination of the described embodiments, features and measures. 

1-19. (canceled)
 20. A pad for use in a beverage machine for preparing a warm beverage, the pad being configured for holding a raw material through which a pressurized flow of liquid is forced for preparing the beverage, the pad comprising: a first sheet having a surface area, wherein the surface area of the first sheet is provided with flow passages that are positioned at or near the outer perimeter of the first sheet; a second sheet having a surface area, wherein the surface area of the second sheet is provided with one or more flow passages that are positioned at or near the centre of the second sheet; and wherein the first sheet and the second sheet are connected to each other at or near the outer perimeter for forming an inner space for holding the raw material that is usable for preparing the beverage, wherein substantially the entire surface area of the first and/or second sheet is impermeable to the flow of pressurized liquid, and wherein the impermeable surface area and the flow passages cooperate for forcing the flow of pressurized liquid to flow substantially in a direction that is parallel to the surface areas through the raw material in the pad.
 21. The pad according to claim 20, wherein a substantial part of the surface area of the first sheet is impermeable to the flow of pressurized liquid and the pad is configured such that in use the first sheet is facing a supply of pressurized flow of liquid.
 22. The pad according to claim 20, wherein the pad is substantially circular, and wherein a diameter of the pad is in the range of 10 to 100 mm, preferably in the range of 35 to 75 mm, and more preferably a diameter of around 60 mm.
 23. The pad according to claim 20, wherein the pad and each of the impermeable surface areas are substantially circular and the diameter of each of the impermeable surface areas is in the range of 50-100% of the diameter of the pad, preferably in the range of 70-100% of the diameter of the pad, and more preferably in the range of 90-95% of the diameter of the pad.
 24. The pad according to claim 20, wherein the first and second sheets are manufactured from a material that is permeable to liquid, such as paper, preferably filterpaper, and wherein the impermeable surface area is formed on one or both of the first and second sheets during manufacturing.
 25. The pad according to claim 24, wherein the forming of the impermeable surface area is performed using one of a group of: coating, spray coating, gluing, printing, rolling, stamping, hot melting or stitching.
 26. The pad according to claim 20, wherein the first and/or the second sheet are manufactured from a material that is impermeable to liquid.
 27. The pad according to claim 24, wherein the impermeable surface area is formed or manufactured from a material that is one of a biodegradable plastic material, such polylactic acid (PLA), or a compostable plastic material or a thermo-compressed paper.
 28. The pad according to claim 20, wherein the impermeable layer comprises an aromatic and/or flavouring substance.
 29. A system for manufacturing pads according to claim 20, the system comprising: a module for manufacturing pads; a module for filling the pads with raw material; and a packing device, which, when viewed in a transport direction, is positioned downstream of the pad manufacturing and pad filling modules; a conveyor which is positioned near an outlet of the pad manufacturing apparatus on which manufactured pads are placeable and that is configured for transporting the pad towards a packing device; a layer application device for applying an impermeable layer to a first and/or second surface of a pad, the impermeable layer extending over at least part of the first and/or second surface, wherein the device is positioned near the conveyor between the outlet and the packing device.
 30. The system according to claim 29, wherein the layer application device is configured to apply an impermeable layer over substantially the entire first and/or second surface of the pad, and wherein the system additionally comprises a passage application device that, when viewed in a transport direction of the conveyor, is positioned downstream of the layer application device and that is configured for applying a number of flow passages in or near the impermeable layer of the pad.
 31. The system according to claim 29, further comprising: a second layer application device that is configured for applying an impermeable layer to another of a first or second surface of the pad; and a second passage application device that, when viewed in a transport direction of the conveyor, is positioned downstream of the second layer application device and that is configured for applying a number of flow passages in or near the impermeable layer on the other surface of the pad.
 32. The system according to claim 29, wherein the first and/or the second layer application device is one of a group of a rotating spray device, a stitching device, a gluing device, a spray gun, impregnating device, or a hot melt device.
 33. The system according to claim 29, wherein the rotation speed of the conveyor is adapted to match the speed of the pad manufacturing apparatus.
 34. A method for manufacturing pads for preparing warm beverages, the method comprising: manufacturing a pad comprising a first and a second sheet, each of the first and second sheet having an outer surface, the manufacturing comprising: sealing the first and second sheet together near an outer edge to form an inner space for holding a raw material; filling the pad with raw material; providing at least one of the first and second outer surfaces with a layer of material that is impermeable to pressurized liquid for, when the pad is used in a beverage machine, creating a flow of pressurized liquid that is substantially in a direction that is parallel to the surface areas through the raw material in the pad; and stacking the pads in a transport container for transporting the pads to users.
 35. The method according to claim 34, the manufacturing step further comprising: supplying an elongated lane of first material for forming first sheets; supplying an elongated lane of second material for forming second sheets; sealing a first and a second sheet along an outer perimeter of a pad to be formed; and punching out the filled pads from the lanes of elongated material.
 36. The method according to claim 34, wherein providing the layer of impermeable material comprises one of a group of coating, spray coating, gluing, printing, rolling, stamping, hot melting, impregnating, providing a self-adhesive layer, or stitching.
 37. The method according to claim 34, the method comprising: applying a first liquid impermeable layer to the first sheet: wherein the surface area of the first impermeable layer is smaller than the outer surface area of the first sheet to provide a flow passage in the first sheet; or wherein, if the surface area of the first impermeable layer is substantially equal to the outer surface area of the first sheet, the applying also comprises applying a number of flow passages in the first sheet near an outer edge thereof for the passage of pressurized liquid; and/or applying a second liquid impermeable layer to the second sheet; and providing a flow passage near a centre of the impermeable layer in the second sheet to allow passage of pressurized liquid.
 38. The method according to claim 37, wherein providing at least one of the first and second outer surfaces with a layer of material that is impermeable to pressurized liquid is executed by manufacturing at least one of the first and second sheet of the pad from a material that is impermeable to pressurized liquid, and wherein the method further comprises applying a number of flow passages in the impermeable sheet or sheets to allow the passage of pressurized liquid.
 39. The system according to claim 30, further comprising: a second layer application device that is configured for applying an impermeable layer to another of a first or second surface of the pad; and a second passage application device that, when viewed in a transport direction of the conveyor, is positioned downstream of the second layer application device and that is configured for applying a number of flow passages in or near the impermeable layer on the other surface of the pad. 